Phono plug and method of making

ABSTRACT

A pin-carrying washer is seated on a shoulder facing toward the mouth end within and intermediate the length of the plug shell and is locked in place by a clamping shoulder crimped radially inwardly in the shell spaced from the seating shoulder. An annular radially outwardly projecting rib between the seating and clamping shoulders reinforces the shell and serves as a finger grip. A method of making the phono plug comprises initially constructing the shell outwardly from the seating shoulder of a diameter slightly larger than the diameter of the washer, inserting the washer through the mouth end of the shell onto the seating shoulder, retaining the shell about the seating shoulder and therebelow against deformation, and collapsing material of the shell wall radially inwardly to provide the clamping shoulder, as by applying axial force to the shell wall toward the seating shoulder.

United States Patent 1 Wallo 1 Mar. 27, 1973 [54] PHONO PLUG AND METHODOF MAKING I [75] lnilentorz William H. Wallo, Chicago, Ill.

[73] Assignee: Wall-Able Manufacturing Corporation, Chicago, Ill.

22 Filed: .July 2,1911

21 Appl.No.: 159,269

[52] US. Cl. ..339/177 R, 29/520, 29/510 [51] Int. Cl. ..1-101r 17/06[58] Field of Search ..29/510, 515, 520, 629; 339/177-183, 136, 142,212, 220

[56] References Cited I UNITED STATES PATENTS 3,295,094 12/1966 DeLyonet a1. ..339/177 R 218,808 8/1879 Austin ..29/510 1,570,320 l/1926Serewicz ..29/520 2,457,789 12/1948 Von Scheven..... ....339/220 L3,600,531 8/1971 Hoegerl ..339/177 E Primary ExaminerJoseph H. McGlynnAssistant Examiner-Lawrence J. Staab Attorney-Carlton Hill et a1.

[57] ABSTRACT A pin-carrying washer is seated on a shoulder facingtoward the mouth end within and intermediate the length of the plugshell and is locked in place by a clamping shoulder crimped radiallyinwardly in the shell spaced from theseating shoulder. An annularradially outwardly projecting rib between the seating and clampingshoulders reinforces the shell and serves as a finger grip.

A method of making the phono plug comprises initially constructing theshell outwardly from the seating shoulder of a diameter slightly largerthan the diameter of the washer, inserting the washer through the mouthend of the shell onto the seating shoulder, retaining the shell aboutthe seating shoulder and therebelow against deformation, and collapsingmaterial of the shell wall radially inwardly to provide the clampingshoulder, as by applying axial force to the shell wall toward theseating shoulder,

11 Claims, 5 Drawing Figures PHONO PLUGAND METHOD OF MAKING Thisinvention relates to phono plugs and a method of making the same, and ismore particularly concerned with the type of phono plug in which anelectrically conductive pin is carried by an insulating washer mountedwithin an electrical conductive shell which is adapted to engagefrictionally about a jack into which the pin is inserted as a plug.

As heretofore constructed, phono plugs have had the insulating washersecured within the shell by press fit, bent over lugs, indentations inthe shell wall gripping the washer perimeter, and the like. Problemshave been encountered with the prior arrangement for several reasonsamong which may be mentioned excessive number of manufacturing steps,unsatisfactory retention of the washer, inaccurate assembly of theparts, failure to hold the washer and plug steady.

An important object of the present invention is to overcome theforegoing and other disadvantages, defects, inefficiencies, shortcomingsand problems in prior structures and methods and to attain importantadvantages and improvements in the structure and method of making phonoplugs, as will become apparent.

Another object of the invention is to provide a new and improved phonoplug in which the pin or plug carrying insulating washer is positivelylocked in place.

Another object of the invention is to provide a phono plug in which thepin-carrying washer is held effectively against turning relative to theshell.

Still another object of the invention is to provide a new and improvedphono plug in which the pin-carrying washer is carried in uniformlylocked relation on a seating shoulder in the shell.

Yet another object of the invention is to provide a new and improvedmethod of making phono plugs.

Other objects, features and advantages of the invention will be readilyapparent from the following description of certain preferred embodimentsthereof, taken in conjunction with the accompanying drawing, althoughvariations and modifications may be effected without departing from thespirit and scope of the novel concepts embodied in the disclosure, andin which:

FIG. 1 is a top plan view of a phono plug shell embodying features ofthe invention;

FIG. 2 is an axial sectional detail view taken substantially along theline "-11 of FIG. 1;

FIG. 3 is a sectional view similar to FIG. 2 illustrating the method ofmaking the phono plug;

FIG. 4 is an axial sectional view through a slightly modified form ofthe phono plug shell; and

FIG. 5 is a similar sectional view showing the completed phono plugassembly embodying the shell of FIG. 4.

On reference to FIGS. 1-3, an electrically conductive phono plug shellis constructed as a one-piece member from suitable thin electricallyconductive material such as brass or cold-rolled steel which can readilybe die stamped, drawn and shaped to provide a tubular body of thedesired configuration and then plated, as is customary, with nickel,cadmium, or as otherwise preferred. One end of the tubular shell 10 isconstructed to provide a mouth within which is received a complementaryreceptacle or phono jack body which is frictionally gripped and retainedby means of mouth-end cooperating gripping fingers 12 separated by slots13 which extend inwardly at uniformly spaced circumferential intervalsfrom the mouth end tip of the body whereby to afford resilient relativeflexibility so that the-fingers can expand radially from a terminalconvergence of the fingers as shown in FIG. 3 for receiving and grippingthe jack body.

At a suitable location intermediate its length, the shell body 11 isprovided with an internal annular shoulder 14 which faces toward themouth end of the shell to receive and seat a plug or pin carryinginsulating disk 15 which may be constructed from fiber, micafilled hardrubber, phenolic material preferably reinforced, polypropylene, ceramicor the like, and is centrally apertured to mount a tubular electricallyconductive, such as nickel-plate brass, plug or pin 18 desirably rivetedthereto in the usual manner. As initially constructed, the shell body 11together with the fingers 12 is of a slightly greater inside diameterfrom the mouth terminus to the shoulder 14 than the outside diameter ofthe disk 15 to be mounted thereon, to enable free and easy assembly. Informing the shoulder 14, it is provided as an offset between theprincipal diameter of the body 11 and a reduced diameter shell bodyportion 19 extending in the opposite direction from which the shoulder14 faces, that is longitudinally or axially away from the fingers 12 andterminating in a further reduced diameter terminal portion 20, as iscustomary.

To lock the disk 15 on its seat shoulder 14, the shell body 11is'provided with a preformed, uniform, annular locking shoulder flange21 suitably spaced in the direction of the mouth end of the shell fromthe fixed shoulder 14 and initially clear of the maximum inside diameterof the shell body 11 to avoid any interference with free and easyassembly of the disk 15 through the shell mouth onto the seat 14. Aftersuch assembly the locking shoulder flange 21 is bent inwardly intolocking engagement with the adjacent margin or at least marginal edge ofthe disk 15 to clamp and retain the disk firmly, and desirablynon-rotatably, on the shoulder 14.

In order to facilitate moving the locking shoulder flange 21 from itsinitial position into the locking,

clamping position with respect to the disk 15, the

flange 21 is initially formed as part of an annular radially outwardlyprojecting and radially inwardly hollow reinforcing rib 22 of which theflange 21 comprises an oblique generally radially inwardly extendingwall portion which slopes toward the mouth end of the shell 10. At itsopposite side, the rib 22 is defined by a way flange 23 which joins agenerally axially extending spacing portion of the shell body 11intervening between the shoulder 14 and the rib 22 and desirably shorterthan the thickness of the disk 15 so that when the disk 15 isinitially'mounted on the shoulder 14, the shell mouth facing surface ofthe disk will be aligned with the shoulder flange 21, and preferablyadjacent to but spaced from the inner end of the shoulder flange in suchrelationship as to enable clamping, locking engagement of the disk upononly slight inward turning, bending displacement of the shoulder flangetoward and against the disk. As will be observed, the shoulder flange 21is sufficiently wider than the flange 23 such that when the flange 21 isdisplaced toward the disk 15 by bending of the flange 21 about a fulcrumat the apex of the annular rib 22, the disk-engaging end portion of theflange 21 will move inwardly to a smaller diameter than the initialinside diameter of the shell body 11. To accommodate such inwarddisplacement, the immediately adjacent annular portion of the body 11 isdisplaced correspondingly radially inwardly providing a radiallyinwardly projecting annular reinforcing rib 24, strengthening thelocking shoulder and providing, in effect, an annular strut 25precluding opening or diskreleasing deflection of the shoulder flange 21but retaining it positively in its locking, clamping condition. Byvirtue of its radially outward projection, the rib 22 serves as aconvenient finger grip surface used for pushing the phono plug intoassembly with a jack, but also for pulling the phono plug whenseparating the same from the jack.

After the disk 15 carrying the pin 18 as a unit therewith is assembledthrough the mouth of the shell 10 onto the seat 14, locking, clamping ofthe disk is adapted to be effected easily, positively, with substantialaccuracy, and expeditiously by axial pressure applied to the shell tocollapse the shoulder flange 21 from its initial clearance positionrelative to the inside diameter of the shell wall 11 into the disklocking and clamping position. Conveniently this is adapted to beeffected in a simple die structure comprising a holding die member 25having a cavity 27 which is complementary to and receives the base orterminal end portion of the shell 10 conformable to its outsidecontours, inclusive of the rib flange 23 and the crest of the rib sothat the rib will be firmly supported against spreading and all portionsof the shell from the rib to and including the terminal and especiallythe shoulder 14 will be firmly held to shape and against deformationwhen relative axial compression is applied to the shell by and betweenthe die member and a cooperating die member 28. Within the die member 28is a forming cavity 29 operatively aligned with the cavity 27 and havinga frusto-conical outwardly opening shaping wall 30 dimensioned to sizethe fingers 12 from an essentially cylindrical initial shape as shown inFIG. 2 into the relatively convergent relationship shown in FIG. 3 toenable efficient frictional resilient gripping of a jack body. Further,the cavity 27 is of a depth such that on completion of the fingershaping, the tips of the fingers will engage the root surface definingthe cavity 29 and enable axis compression thrust to be imparted to theshell 10 by and between the die members 25 and 28 to effect collapsingdisplacement of the clamping and locking flange shoulder 21 inwardlyonto the disk 15, accompanied by the inward displacement of the rib 24and the strut flange 25. As such axial compression occurs, the diemember 25 holds the rib 22 firmly against spreading to thereby assureproper, intended inward displacement movement of the flange 21 and theannular portion of the body 11 which forms the inward rib 24 and thestrut 25.

In the slightly modified structure of FIGS. 4 and 5, essential featuresare substantially the same as in the form already described and assemblyof the parts is effected in the same manner so that description of andin respect to one form will suffice for the other. Accordingly, primedreference numerals have been applied to FIGS. 4 and 5 and thedescription of the designated elements can be considered the same exceptas to the slight modifications to be pointed out. Thus, in FIGS. 4 and 5the shell 10 has the portion 19' between the shoulder 14' and theterminal 20' of generally frusto-conical shape rather than the generallycylindrical shape shown in FIGS. 2 and 3. By having the rib 22 initiallyof a more rounded or radius crest formation, the clamping and lockingshoulder 21 may assume a position generally normal to the axis of theassembly in the clamping and locking position, as shown in FIG. 5. Thismay be advantageous for clamping and locking the disk 15 onto theshoulder 14 where extreme care must be taken not to overstress thematerial of the disk due to brittleness or other factors. As will beobserved the clamping pressure may thus be imposed by the shoulderflange 21 more nearly in a direction normal to the plane of the shoulder114, as compared to the more biased direction of clamping pressure thatmay be imposed on the disk margin in the form of FIG. 3.

It will be understood that variations and modifications may be effectedwithout departing from the spirit and scope of the novel concepts ofthis invention.

I claim as my invention:

1. In a phono plug structure:

a tubular one-piece electrically conductive shell body having a mouth atone end defined by jackbody-gripping fingers and having a terminal atits opposite end;

an integral intermediate internal pin-disk-seating shoulder on said bodyfacing toward said fingers;

an annular radially outwardly projecting and radially inwardly openinghollow rib integral with said body and having one wall in partcomprising a shoulder flange; and

a spacing portion of the body intervening between the shoulder and asecond wall of the rib which joins said intervening portion; whereby toenable clamping, locking engagement of the disk against said shoulderupon only slight inward displacement of said shoulder flange.

2. A structure according to claim 1, wherein said shoulder flangeextends at least initially in slanting relation to said second wall andgenerally obliquely toward said fingers.

3. A structure according to claim 1, said flange and said one wall beingwider than said second wall whereby the shoulder flange will overhangsaid shoulder for clamping the disk thereto.

4. A structure according to claim 1, having in combination therewith aninsulating disk seated on said shoulder and carrying a plug pin, saidshoulder flange engaging against the disk and thereby clamping andlocking the disk onto said shoulder, and a generally radially inwardlydirected strut flange integral with said body and reinforcing saidshoulder flange.

5. In a phono plug structure:

a tubular one-piece electrically conductive shell body having a mouth atone end defined by jackbody-gripping fingers and having a terminal atits opposite end;

an integral intermediate internal pin-disk-seating shoulder on said bodyfacing toward said fingers;

an insulating disk seated on said shoulder and carrying a plug pin;

an annular integral shoulder flange on said body facing toward saidshoulder and engaging against the disk and clamping and locking the diskonto said shoulder;

an annular radially outwardly projecting rib joining said shoulderflange to the body adjacent to said shoulder; and

the portion of the body between said shoulder and said rib being shorterthan the thickness of said disk.

6. A structure according to claim 5, in which said shoulder flangeextends substantially parallel to the disk.

7. In a phono plug structure:

a tubular one-piece electrically conductive shell body formed from thinmaterial will a mouth at one end defined by jack-body-gripping fingersand having a terminal at its opposite end;

an integral intermediate internal pin-disk-seating shoulder on said bodyfacing towards said fingers;

an insulating disk carrying a plug pin and seated on said shoulder;

said body having an annular generally axially extending portion thereofabout said disk and including a radially outwardly projecting hollowreinforcing rib axially spaced from said shoulder by said annularportion; and

a radially inwardly crimped shoulder portion of said reinforcing ribclamping the disk against the seating shoulder.

8. In a method of making a phono plug structure:

assembling a pin-carrying insulating washer onto an internal shoulderintermediately in a tubular electrical conductive shell;

displacing an integral annular flanger in said body from a clearancerelation to said shoulder into clamping locking engagement with saiddisk and thrusting toward said shoulder; and

shaping and sizing gripping fingers on said shell body generallyradially outwardly projecting annular rib on said shell between saidshoulder and said shoulder flange to size, and displacing an annularreinforcing rib l0 radially inwardly in the body along a generallyradially inwardly projecting end portion of said shoulder flangeoverlying the disk.

10. In a method of making a phono plug structure:

shaping a one-piece shell from a suitable thin electrically conductivematerial to provide a tubular body with gripping fingers at one end;

shaping an internal seating shoulder intermediately in said body with anaxially extending portion of the body extending from said shoulder;

shaping an integral radially outwardly extending hollow rib on saidtubular body, said hollow rib being spaced a limited distance from saidshoulder by said axially extending portion;

assembling a pin-carried insulating washer onto said shoulder and havinga thickness greater than said axially extending portion between saidshoulder and said rib; and crimping in said body ad acent to saidfingers a radiing and sizing the gripping fingers from a normallygenerally cylindrical position into generally convergent relationincident to shaping said radially inwardly extending rib.

Dedication 3,723,949.--William H. Walla, Chicago, 111. PHONO PLUG ANDMETHOD OF MAKING SAME. Patent dated Mar. 27, 1973. Dedication filed Jan. 13, 1975, by the assignee, Wall Able Tool 0'2: Die 00130.

Hereby dedicates t0 the Public the remaining term of said. patent.

[Ofloial Gazette April 8, 1.975.]

1. In a phono plug structure: a tubular one-piece electricallyconductive shell body having a mouth at one end defined byjack-body-gripping fingers and having a terminal at its opposite end; anintegral intermediate internal pin-disk-seating shoulder on said bodyfacing toward said fingers; an annular radially outwardly projecting andradially inwardly opening hollow rib integral with said body and havingone wall in part comprising a shoulder flange; and a spacing portion ofthe body intervening between the shoulder and a second wall of the ribwhich joins said intervening portion; whereby to enable clamping,locking engagement of the disk against said shoulder upon only slightinward displacement of said shoulder flange.
 2. A structure according toclaim 1, wherein said shoulder flange extends at least initially inslanting relation to said second wall and generally obliquely towardsaid fingers.
 3. A structure according to claim 1, said flange and saidone wall being wider than said second wall whereby the shoulder flangewill overhang said shoulder for clamping the disk thereto.
 4. Astructure according to claim 1, having in combination therewith aninsulating disk seated on said shoulder and carrying a plug pin, saidshoulder flange engaging against the disk and thereby clamping andlocking the disk onto said shoulder, and a generally radially inwardlydirected strut flange integral with said body and reinforcing saidshoulder flange.
 5. In a phono plug structure: a tubular one-pieceelectrically conductive shell body having a mouth at one end defined byjack-body-gripping fingers and having a terminal at its opposite end; anintegral intermediate internal pin-disk-seating shoulder on said bodyfacing toward said fingers; an insulating disk seated on said shoulderand carrying a plug pin; an annular integral shoulder flange on saidbody facing toward said shoulder and engaging against the disk andclamping and locking the disk onto said shoulder; an annular radiallyoutwardly projecting rib joining said shoulder flange to the bodyadjacent to said shoulder; and the portion of the body between saidshoulder and said rib being shorter than the thickness of said disk. 6.A structure according to claim 5, in which said shoulder flange extendssubstantially parallel to the disk.
 7. In a phono plug structure: atubular one-piece electrically conductive shell body formed from thinmaterial will a mouth at one end defined by jack-body-gripping fingersand having a terminal at its opposite end; an integral intermediateinternal pin-disk-seating shoulder on said body facing towards saidfingers; an insulating disk carrying a plug pin and seated on saidshoulder; said body having an annular generally axially extendingportion thereof about said disk and including a radially outwardlyprojecting hollow reinforcing rib axially spaced from said shoulder bysaid annular portion; and a radially inwardly crimped shoulder portionof said reinforcing rib clamping the disk against the seating shoulder.8. In a method of making a phono plug structure: assembling apin-carrying insulating washer onto an iNternal shoulder intermediatelyin a tubular electrical conductive shell; displacing an integral annularflanger in said body from a clearance relation to said shoulder intoclamping locking engagement with said disk and thrusting toward saidshoulder; and shaping and sizing gripping fingers on said shell bodyfrom a normally generally cylindrical position into generally convergentrelation as an incident to applying endwise compression to the shell fordisplacing said shoulder flange into the clamping and locking position.9. In a method according to claim 8, retaining a generally radiallyoutwardly projecting annular rib on said shell between said shoulder andsaid shoulder flange to size, and displacing an annular reinforcing ribradially inwardly in the body along a generally radially inwardlyprojecting end portion of said shoulder flange overlying the disk. 10.In a method of making a phono plug structure: shaping a one-piece shellfrom a suitable thin electrically conductive material to provide atubular body with gripping fingers at one end; shaping an internalseating shoulder intermediately in said body with an axially extendingportion of the body extending from said shoulder; shaping an integralradially outwardly extending hollow rib on said tubular body, saidhollow rib being spaced a limited distance from said shoulder by saidaxially extending portion; assembling a pin-carried insulating washeronto said shoulder and having a thickness greater than said axiallyextending portion between said shoulder and said rib; and crimping insaid body adjacent to said fingers a radially inwardly extending ribwith a flange common to said radially outwardly extending rib intoclamping locking engagement with the disk thrusting it toward saidshoulder.
 11. A method according to claim 10, including shaping andsizing the gripping fingers from a normally generally cylindricalposition into generally convergent relation incident to shaping saidradially inwardly extending rib.